Integrated door module

ABSTRACT

A door assembly includes a carrier panel attachable to a vehicle door outer structure such that the carrier panel substantially covers an opening of the door outer structure. The carrier panel is configured to function as a water shield between the door outer structure and a vehicle occupant compartment. The carrier panel also includes an upper portion and a lower portion, and the lower portion defines a lower appearance surface. The assembly further includes a hardware component mounted to and supported by the carrier panel, and an upper trim panel arrangement that is attachable to the carrier panel after the carrier panel has been attached to the door outer structure. The upper trim panel arrangement is configured to substantially cover the upper portion of the carrier panel and defines an upper appearance surface.

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] The invention relates to a door assembly for use with a motorvehicle having a door outer structure and an interior occupantcompartment.

[0003] 2. Background Art

[0004] Various door assemblies have been developed for use with motorvehicles. Such door assemblies are configured to be mounted onto avehicle door outer structure, which may include an outer panel and aninner panel or frame. Examples of prior door assemblies are disclosed inU.S. Pat. Nos. 4,648,208, 4,882,842 and 5,095,659.

[0005] Another prior door assembly includes a carrier panel made offoamed polypropylene and a trim panel made of injection moldedpolypropylene. The carrier panel is attachable to a door outer structureof a vehicle, and the trim panel is attachable to the carrier panel withfasteners, after the carrier panel has been attached to the door outerstructure. Furthermore, the trim panel defines the entire appearancesurface of the door assembly.

SUMMARY OF THE INVENTION

[0006] Under the invention, a door assembly is provided for use with amotor vehicle having a door outer structure and an interior occupantcompartment, wherein the door outer structure has an opening. Theassembly includes a carrier panel adapted to be attached to the doorouter structure such that the carrier panel substantially covers theopening. The carrier panel has a first side adapted to face toward theinterior compartment and a second side adapted to face the door outerstructure. Furthermore, the carrier panel is configured to function as awater shield between the door outer structure and the occupantcompartment for inhibiting water from passing from the second side tothe first side. The carrier panel also includes an upper portion and alower portion. The lower portion defines a lower, finished appearancesurface that is adapted to face the occupant compartment. The assemblyfurther includes a vehicle door hardware component mounted to andsupported by the carrier panel, and an upper trim panel that isattachable to the carrier panel after the carrier panel has beenattached to the door outer structure. The upper trim panel is configuredto substantially cover the upper portion of the carrier panel and havingan upper, finished appearance surface that is adapted to face theoccupant compartment.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007]FIG. 1 is a perspective view of a door assembly according to theinvention mounted to a door outer structure;

[0008]FIG. 2 is a partially exploded view of the door assembly, whichincludes a carrier module that is attachable to the door outerstructure, and an upper trim panel arrangement that is attachable to thecarrier module and/or door outer structure;

[0009]FIG. 3 is a rear exploded view of the carrier module; and

[0010]FIG. 4 is a front exploded view of the carrier module.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

[0011]FIGS. 1 and 2 show a door assembly 10 according to the inventionfor use with a vehicle having a door outer structure 12 and an interioroccupant compartment. The door outer structure 12 may be a metallicstructure and includes an outer panel 14 and an inner panel 16 attachedto the outer panel 14. The door outer structure 12 may also include areinforcing member, such as lateral support 18, attached to the outerpanel 14 and/or inner panel 16. Furthermore, the inner panel 16 has anopening 20 for receiving the door assembly 10, and the opening 20 has amaximum height h and a maximum width w.

[0012] The door assembly 10 includes an integrated door module orcarrier module 22 that is attachable to the door outer structure 12, andan upper trim panel arrangement 24 that is attachable to the carriermodule 22 and/or door outer structure 12. Referring to FIGS. 2-4, thecarrier module 22 includes a carrier panel 26 that is adapted to beattached to the door outer structure 12 such that the carrier panel 26substantially covers the opening 20. In other words, the carrier panel26 is adapted to span the height h and width w of the opening 20. Thecarrier panel 26 has a first side 28 adapted to face toward the interiorcompartment, and a second side 30 adapted to face the door outerstructure 12. In addition, the carrier panel 26 is configured tofunction as a water shield between the interior compartment and the doorouter structure 12 for inhibiting water from passing from the secondside 30 to the first side 28. The carrier panel 26 further includes anupper portion 32 and a lower portion 34, and the lower portion 34defines a lower, finished appearance surface 36. The lower appearancesurface 36 may comprise approximate 20 to 40 percent, for example, ofthe entire appearance surface of the door assembly 10. As shown in FIGS.2 and 4, the lower portion 34 may also include a projecting section orprojection 37 that extends inwardly beyond the upper portion 32.

[0013] Still referring to FIGS. 2-4, the carrier panel 26 includes acarrier panel body 38 that is adapted to span the height h and width wof the opening 20. The carrier panel body 38 may include a main portion40 and a lower back portion 42 that is attached to the main portion 40so as to define a map pocket 44. With this configuration, the mainportion 40 defines the upper portion 32, including the first and secondsides 28 and 30, respectively, of the upper portion 32. The main portion40 also defines the projection 37 of the lower portion 34. Furthermore,the back portion 42 defines the remainder of the lower portion 34,including the first and second sides 28 and 30, respectively, of thelower portion 34. Alternatively, the carrier panel body 38 may be formedas a single piece, or multiple pieces that are attached together. Thecarrier panel body 38 may also include one or more access apertures,such as holes 46 and 48 and slot 50, for providing access to componentsof the door assembly 10 and/or door outer structure 12, as explainedbelow in greater detail.

[0014] The carrier panel body 38 may be made in any suitable manner andmay comprise any suitable material or materials such that the carrierpanel body 38 has sufficient strength to support, at least temporarily,one or more vehicle door hardware components, as explained below ingreater detail. For example, the main portion 40 and/or the back portion42 may be formed of injection molded or compression molded plastic, suchas polypropylene. Furthermore, the plastic may be reinforced withnatural and/or synthetic fibers or other particles. As another example,the main portion 40 and/or back portion 42 may be formed of foamedplastic material, such as foamed polypropylene, foamed polyethylene andfoamed urethane. Such foamed plastic material is formed with a resinrich exterior surface and a foam interior. Other suitable materials forthe carrier panel body 38 include acrylanitrile butadiene styrene (ABS)and glass-fiber mat reinforced thermoplastic material (GMT).

[0015] In the embodiment shown in FIG. 3, the main portion 40 is made ofa structural, moisture impermeable material, such as one or more of thematerials described above, and the back portion 42 is made of aflexible, moisture impermeable material such as expanded polypropylene.With such a configuration, the back portion 42 may also include one ormore integrally formed energy management members, such as impact blocks51.

[0016] The carrier panel body 38 may also define a portion or all of thelower appearance surface 36. For example, the lower appearance surface36 may be provided as a painted surface or an integrally molded coloredand/or grained surface of the main portion 40. Alternatively, thecarrier panel 26 may include a cover material 52 that is attached to thecarrier panel body 38 and that defines a portion or all of theappearance surface 36. The cover material 52 may comprise any suitablematerial, such as vinyl, carpet, leather, etc.

[0017] The carrier panel 26 may also include a seal 53 disposed about anouter periphery of the carrier panel body 38. The seal 53 is adapted tomate with the inner panel 16 so as to seal the carrier panel 26 againstthe inner panel 26 when the carrier panel is mounted to the door outerstructure 12.

[0018] The carrier module 22 further includes one or more vehiclehardware components mounted to the carrier panel 26. In the embodimentshown in FIGS. 3 and 4, for example, the carrier module 22 includes adoor latch assembly 54, a window regulator or lift mechanism 56, aconductive assembly 58 and a speaker 60 mounted to the carrier panel 26.The door latch assembly 54 includes a door latch 62 mounted in anysuitable manner on second side 30 of the carrier panel 26. The doorlatch assembly 54 further includes an interior handle mechanism 64mounted on first side 28 of the carrier panel 26, and actuating cablesor links 66 and 68 extending between and connected to door latch 62 andhandle mechanism 64.

[0019] The window lift mechanism 56 includes a motor 70 mounted on thefirst side 28 or the second side 30 of the carrier panel 26, and a pairof window regulator arms 72 mounted on the second side 30 for supportingan associated door window 74 for vertical movement. The motor 70 andregulator arms 72 may be mounted to the carrier panel 26 in any suitablemanner, such as with fasteners. Alternatively, the motor 70 may beattached to one of the regulator arms 72. In the embodiment shown inFIG. 3, each regulator arm 72 is fixedly mounted to the carrier panel 26in a substantially vertical use position, such that the regulator arms72 are unable to rotate with respect to the carrier panel 26. With sucha configuration, the regulator arms 72 may be fully supported by thecarrier panel 26 after the door assembly 10 has been fully assembled tothe door outer structure 12. Alternatively, the regulator arms 72 may bepivotally mounted to the carrier panel 26 such that the regulator arms72 may be rotated into use positions after the carrier panel 26 has beenattached to the door outer structure 12. With such a configuration, theregulator arms 72 may also be attached to the inner panel 16 of the doorouter structure 12 after the regulator arms 72 have been rotated intothe use positions.

[0020] The window lift mechanism 56 also includes a cable 76 thatextends along each regulator arm 72 between ends thereof, and betweenthe regulator arms 72 in a crossing manner. The cable 76 has a pair ofwindow connectors 78 respectively associated with the regulator arms 72to provide connection to the door window 74. Each window connector 78 ismovable along a respective regulator arm 72 to enable vertical movementof the door window 74.

[0021] Alternatively, the window lift mechanism 56 may have any suitableconfiguration and include any suitable components. For example, thewindow lift mechanism 56 may include only one regulator arm.

[0022] The conductive assembly 58 may be a wire harness that includesvarious conductive elements, such as wires 80, and associated electricalconnectors 82, 83 and 84 for operating electrical components of the doorassembly 10, such as door latch assembly 54, window lift mechanism 56,speaker 60, a vehicle seat control, a mirror control, etc. In theembodiment shown in FIG. 4, the electrical connectors 83 and 84 areconfigured to be self-docking, as explained below in greater detail. Aplurality of jumper wires 86 may also be connected between theconductive assembly 58 and the electrical components. Each jumper wire86 may include one or more wires 88 and associated electrical connectors90.

[0023] The carrier module 22 may also include one or more additionalvehicle door hardware components mounted to the carrier panel 26. Forexample, the carrier module 22 may include a side impact restraint, suchas air bag 92, connected to the main portion 40 and/or back portion 42and disposed between the main portion 40 and back portion 42. Additionaldetails regarding components that may be attached to carrier panel 26are disclosed in co-pending application Ser. No. 09/690,635, which ishereby incorporated by reference.

[0024] Referring to FIG. 2, the upper trim panel arrangement 24 isattachable to the carrier panel 26 and/or door outer structure 12 afterthe carrier panel 26 has been attached to the door outer structure 12.For example, the upper trim panel arrangement 24 may be snap fit and/orattached with fasteners to the carrier panel 26 and/or door outerstructure 12. The upper trim panel arrangement 24 is configured tosubstantially cover the upper portion 32 of the carrier panel 26, andhas an upper, finished appearance surface 93 that is adapted to face theinterior compartment. Furthermore, the upper trim panel arrangement 24may include multiple upper trim panel portions, such as arm bolsterportion 94 and top portion 96 that are attachable together.Alternatively, the upper trim panel arrangement 24 may be provided as asingle panel or module. In any case, the configuration and materials ofthe upper trim panel arrangement 24 may be varied from vehicle tovehicle so as to provide aesthetic flexibility and brand-identificationflexibility.

[0025] The arm bolster portion 94 defines a first or lower surfaceportion 97 of the upper appearance surface 93, and may include a bolsterportion body 98 and one or more cover materials, such as cover material100, attached to the bolster portion body 98. The bolster portion body98 may comprise any suitable material, such as one or more of thematerials described above with respect to the carrier panel body 38. Thecover material 100 may define some or all of the lower surface portion97, and may comprise any suitable cover material, such as cloth, carpet,vinyl, leather, etc. Alternatively, the arm bolster portion 94 may beprovided without a cover material attached to the bolster portion body98. With such a configuration, the bolster portion body 98 defines theentire lower surface portion 97.

[0026] The arm bolster portion 94 may further include a control unit,such as a switch pack 102, attached to the bolster portion body 98 suchas by a snap fit. The switch pack 102 may include controls or switches104 for controlling various vehicle components, such as window liftmechanism 56, a power door lock mechanism, a vehicle seat, an automaticmirror, etc. The switch pack 102 may also include a self-dockingconnector that mates with the connector 83 of the connector assembly 58.

[0027] The top portion 96 defines a second or upper surface portion 105of the upper appearance surface 93, and may include a top portion body106 and one or more cover materials, such as cover material 108,attached to the top portion body 106. The top portion body 106 maycomprise any suitable material, such as one or more of the materialsdescribed above with respect to the carrier panel body 38. Furthermore,the cover material 108 may define some or all of the upper surfaceportion 105, and may comprise, for example, cloth, carpet, vinyl,leather, or any other suitable cover material. Alternatively, the topportion 96 may be provided without a cover material attached to the topportion body 106. With such a configuration, the top portion body 106defines the entire upper surface portion 105.

[0028] Referring to FIGS. 2-4, a method according to the invention ofmanufacturing door assembly 10 will now be described. As mentioned abovethe carrier panel body 38 may be made in any suitable manner and maycomprise any suitable material. In one embodiment of the invention, themain portion 40 is made of foamed plastic material using a gas-injectionmolding process. Such a process may include, for example, injectingpolypropylene or other suitable plastic material into a mold, and theninjecting a gas, such as nitrogen, into the plastic material so as tocreate a foam interior portion surrounded by a resin rich surface. Theresin rich surface forms a solid plastic shell or layer around the foaminterior portion. With such a configuration, the foamed plastic materialis strong yet light weight.

[0029] In one embodiment of the invention, the back portion 42 is formedof expanded polypropylene. The back portion 42 is then heat staked orotherwise attached to the main portion 40. The air bag 92 may also beattached to the main portion 40 and/or back portion 42, prior toattaching the back portion 42 to the main portion 40.

[0030] Next, the conductive assembly 58 may be attached to the firstside 28 or second side 30 of the main portion 40 such as with adhesiveand/or fasteners. The conductive assembly 58 may be a preassembled wireharness structure as described above, or the conductive assembly 58 maybe integrated with the carrier panel 26. For example, the conductiveassembly 58 may include a conductive element or trace pattern, such as ametal trace pattern, that may be attached to the main portion 40. Aplasma layer may then be sprayed over the trace pattern so as toinsulate the traces from each other as well as the surroundings. Theconnectors 82, 83 and 84 may then be connected to the trace pattern, andthe jumper wires 86 may be connected to the connectors 82, 83 and 84.

[0031] Next, the door latch assembly 54 is attached to the carrier panel26 For example, a projecting portion of the door latch 62 may be slidinto a channel 110 integrally formed on the second side 30 of the mainportion 40, and one or more fasteners may be used to secure the doorlatch 62 in a desired position. The actuating links 66 and 68 may berouted through integrally formed clamp features 112 of the main portion40, and then into holes 114 of a handle receptacle 116 of the mainportion 40. Seals associated with the actuating links 66 and 68 are thenseated in the holes 114.

[0032] The regulator arms 72 and cable 76 of the window lift mechanism56 may also be mounted to the second side 30 of the main portion 40and/or back portion 42 of the carrier panel 26. If the regulator arms 72are fixedly mounted to the carrier panel 26, then the access slot 50 maybe eliminated from the carrier panel 26. If the regulator arms 72 arepivotally mounted to the carrier panel 26, then the access slot 50 mayprovide access to the regulator arms 72 after the carrier panel 26 hasbeen mounted to the door outer structure 12. As mentioned above, thewindow lift mechanism 56 may be provided with only one regulator arm.With such a configuration, the window lift mechanism 56 may also includetwo glass guides (not shown) mounted to the carrier panel on oppositesides of the regulator arm.

[0033] Next, the motor 70 may be mounted on the first side 28 of themain portion 40 and/or back portion 42 such that the motor 70 is indriving relationship with the cable 76. For example, a rotatable shaft118 may be positioned between the motor 70 and the cable 76.

[0034] The speaker 60 may also be mounted on the carrier panel 76. Inaddition, one or more of the jumper wires 86 may be used to connect theconductive assembly 58 to the speaker 60, as well as other electricalcomponents such as the door latch 62 and motor 70.

[0035] The bolster portion body 98 of the arm bolster portion 94 may bemanufactured in any suitable manner, such as by an injection moldingprocess or compression molding process. Furthermore, the cover material100, if used, may be molded with the bolster portion body 98, orsubsequently attached to the formed bolster portion body 98. The switchpack 102 is then attached to the bolster portion body 98.

[0036] The top portion 96 may be manufactured in a similar manner as thearm bolster portion 94. Alternatively, as mentioned above, the uppertrim panel arrangement 24 may be formed as a single panel, or any numberof panels that are attachable together and/or to the carrier module 22.

[0037] Referring to FIGS. 1 and 2, a method of assembling the doorassembly 10 to the door outer structure 12 will now be described. First,a connector arrangement 120 may be positioned in the door outerstructure 12. The connector arrangement 120 is configured toelectrically connect the conductive assembly 58 with vehicle bodywiring, such as a body harness (not shown), and includes first andsecond connectors 122 and 124, respectively. The first connector 122 isattachable to the body harness (not shown), and the second connector124, which may be a self-docking connector, is attachable to theconductive assembly 58.

[0038] Next, the carrier module 22 is positioned proximate the opening20 of the door outer structure 12 so that the connector 84 is positionedproximate the second connector 124. The carrier module 22 is thenattached to the door outer structure 12 such that such that theconnector 84 mates with the second connector 124, and such that thecarrier panel 26 substantially covers the opening 20.

[0039] If the carrier module 22 includes one or more regulator arms 72that are pivotally connected to the carrier panel 26, the method mayalso include inserting a tool, such as a screwdriver, through the slot50 after the carrier panel 26 has been attached to the door outerstructure 12. The tool may then be used to rotate the regulator arms 72with respect to the carrier panel 26 and into substantially vertical usepositions. Next, the regulator arms 72 may be secured to the inner panel16 with fasteners.

[0040] The holes 46 and 48 and slot 50, as well as any other aperturesin the carrier panel body 38, may then be covered with patches 126. Thepatches 126 may comprise any suitable material, such as closed-cellfoam, and may be attached to the carrier panel body 38 in any suitablemanner, such as with adhesive.

[0041] Next, the arm bolster portion 94 is attached against the upperportion 32 such that the self docking connector of the switch pack 102mates with the connector 83 of the conductive assembly 58. The topportion 96 is then positioned above the arm bolster portion 94 andattached against the upper portion 32, such that the arm bolster portion94 and top portion 96 cooperate to substantially cover the first side 28of the upper portion 32. The arm bolster portion 94 and top portion 96also cooperate to define the upper appearance surface 93. A door handlebezel 128 may then be positioned around the door handle 67.

[0042] Under the invention, a common carrier module may be used for avariety of vehicles. Advantageously, different upper appearance surfacesand brand identifications may be achieved by using different upper trimpanel arrangements. Furthermore, an upper trim panel arrangement, orportion thereof, may be replaced if damaged.

[0043] While embodiments of the invention have been illustrated anddescribed, it is not intended that these embodiments illustrate anddescribe all possible forms of the invention. Rather, the words used inthe specification are words of description rather than limitation, andit is understood that various changes may be made without departing fromthe spirit and scope of the invention.

What is claimed is:
 1. A door assembly for use with a motor vehiclehaving a door outer structure and an interior occupant compartment,wherein the door outer structure has an opening for receiving the doorassembly, the assembly comprising: a carrier panel adapted to beattached to the door outer structure such that the carrier panelsubstantially covers the opening, the carrier panel having a first sideadapted to face toward the occupant compartment and a second sideadapted to face the door outer structure, the carrier panel beingconfigured to function as a water shield between the door outerstructure and the occupant compartment for inhibiting water from passingfrom the second side to the first side, the carrier panel furtherincluding an upper portion and a lower portion, the lower portiondefining a lower, finished appearance surface that is adapted to facethe occupant compartment; a vehicle door hardware component mounted toand supported by the carrier panel; and an upper trim panel arrangementthat is attachable to the carrier panel after the carrier panel has beenattached to the door outer structure, the upper trim panel arrangementbeing configured to substantially cover the upper portion of the carrierpanel and having an upper, finished appearance surface that is adaptedto face the occupant compartment.
 2. The door assembly of claim 1wherein the carrier panel includes a carrier panel body and a covermaterial attached to the carrier panel body, the cover material definingthe lower, finished appearance surface.
 3. The door assembly of claim 1wherein the opening has a height and a width, and the carrier panelincludes a carrier panel body that is adapted to span the height and thewidth of the opening.
 4. The door assembly of claim 3 wherein thecarrier panel body defines the lower, finished appearance surface. 5.The door assembly of claim 3 wherein the carrier panel body comprisesplastic.
 6. The door assembly of claim 3 wherein the carrier panel bodycomprises polypropylene.
 7. The door assembly of claim 3 wherein thecarrier panel body comprises foamed plastic material.
 8. The doorassembly of claim 3 wherein the carrier panel body comprisesthermoplastic material reinforced with fiberglass.
 9. The door assemblyof claim 3 wherein the carrier panel body includes an access slotconfigured to receive a positioning tool that is used to position thevehicle door hardware component relative to the carrier panel body afterthe carrier panel has been attached to the door outer structure.
 10. Thedoor assembly of claim 9 wherein the carrier panel includes a sealerpatch that is attachable to the carrier panel body for covering theaccess slot after the vehicle door hardware component has beenpositioned.
 11. The door assembly of claim 3 wherein the carrier panelbody includes a main portion and a back portion attached to the mainportion, wherein the main portion and the back portion cooperate todefine a map pocket.
 12. The door assembly of claim 1 further comprisingmultiple vehicle door hardware components mounted to and supported bythe carrier panel, the components including a door latch mechanism and awindow regulator mechanism, the door latch mechanism including an innerdoor handle mounted on the first side of the carrier member, and a latchassembly connected to the door handle and mounted on the second side ofthe carrier member, the window regulator mechanism including a motormounted on the first side of the carrier member, and a window regulatorarm mounted on the second side of the carrier member.
 13. The doorassembly of claim 1 wherein the vehicle door hardware component is awindow regulator mechanism that includes a pair of window regulator armsfixedly attached to and fully supported by the carrier panel, such thatthe window regulator arms are not directly attachable to the door outerstructure.
 14. A method for making a vehicle door for use with a vehiclehaving an interior occupant compartment, the method comprising:positioning a carrier module proximate a vehicle door outer structurehaving an opening, the carrier module including a carrier panel and avehicle door hardware component attached to the carrier panel, thecarrier panel including first and second sides and upper and lowerportions, the lower portion having a lower, finished appearance surfacefor facing the occupant compartment; attaching the carrier panel to thedoor outer structure such that the carrier panel substantially coversthe opening; and securing an upper trim panel arrangement against thecarrier panel after the carrier panel has been attached to the doorouter structure such that the upper trim panel arrangement substantiallycovers the first side of the upper portion, the upper trim panelarrangement having an upper, finished appearance surface for facing theoccupant compartment; wherein the carrier panel is configured tofunction as a water shield for inhibiting water from passing from thesecond side to the first side of the carrier panel.
 15. The method ofclaim 14 wherein the carrier panel includes a carrier panel body havingan access aperture, and wherein the method further comprises inserting atool through the access aperture, after the carrier panel has beenattached to the door outer structure, and positioning the vehicle doorhardware component relative to the carrier panel using the tool.
 16. Themethod of claim 15 further comprising attaching an access patch to thecarrier panel body, after the vehicle door hardware component has beenpositioned, so as to cover the access aperture.
 17. The method of claim14 wherein the vehicle door hardware component is a window regulatormechanism that includes two window regulator arms fixedly attached tothe carrier panel such that each regulator arm is in a use position withrespect to the carrier panel prior to the positioning step, and whereinthe step of attaching the carrier panel to the door outer structure isperformed such that the window regulator arms remain in the usepositions.
 18. A method for making a vehicle door for use with a vehiclehaving an interior occupant compartment, the method comprising: forminga carrier panel body from plastic material, the carrier panel bodyhaving first and second sides and upper and lower portions, the upperportion having an access aperture extending therethrough, the lowerportion having a lower, finished appearance surface for facing theoccupant compartment; mounting a window regulator arm to the carrierpanel body; attaching the carrier panel body to a vehicle door outerstructure having an opening such that the carrier panel bodysubstantially covers the opening, inserting a tool through the accessaperture after the carrier panel body has been attached to the doorouter structure; rotating the window regulator arm with respect to thecarrier panel body using the tool; securing the window regulator arm tothe door outer structure; attaching a sealing patch to the carrier panelbody so as to cover the access aperture; and securing an upper trimpanel arrangement against the carrier panel after the window lift guidehas been attached to the door outer structure such that the upper trimpanel arrangement substantially covers the first side of the upperportion, the upper trim panel arrangement having an upper, finishedappearance surface for facing the occupant compartment; wherein thecarrier panel body is configured to function as a water shield forinhibiting water from passing from the second side to the first side ofthe carrier panel body.